M.C.C.S.INTERNATIONAL

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2 M.C.C.S.INTERNATIONAL Mechanical Completion and Commissioning Services Ltd. Formed in 1994 To fill a niche market in the area of Mechanical Completion and Commissioning M.C.C.S. Worldwide Ltd. Formed 2000 in the UK M.C.C.S. Worldwide Sdn Bhd Formed 2001 Kuala Lumpur Malaysia and renamed to M.C.C.S. International Sdn Bhd 2007 Branch Offices in UK, Spain, Vietnam and Indonesia What makes M.C.C.S. unique? M.C.C.S. comprises a team of people who have specialised in this difficult area for several years. The principle spin off from this team approach is The Wheel is not Reinvented Maximise cost benefits M.C.C.S. involvement should be sought during the early planning and design phase of a project. Within schedule and under budget M.C.C.S. team has an enviable record of achieving its tasks within schedule and under budget.

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4 MCCS PROFESSIONAL SERVICES FOR FLANGE MANAGEMENT FOR EPCC / EPCIC OIL & GAS PROJECTS JANUARY.2015 CARMEN

5 INTRODUCTION TO FLANGE MANAGEMENT SYSTEM PROVIDING SERVICES, SUPERVISION AS WELL AS DOCUMENT MANAGEMENT (DATABASE / CERTIFICATES PROVIDED) FROM ASSEMBLY, BOLTING, BREAKOUT, REPAIR UP TO FINAL INSPECTION. PROCESS OF WHICH ASSEMBLY OF SYSTEM FLANGES ARE IN A CONTROLLED MANNER. OVERSEEING INSTALLATION OF PIPELINES THROUGH INSPECTION OF FLANGES DATABASE INPUT AND CERTIFICATION OF JOINTS ASSEMBLE IN ACCORDANCE TO REQUIRED TORQUE / TENSION VALUES VERIFICATION OF MATERIALS USED PRIOR TO JOINTS ASSEMBLY THE TECHNOLOGY COMBINED WITH CAPABILITIES OF MCCS INTERNATIONAL, RESULTS IN AUDITABLE REPORT CONFIRMING SYSTEM SAFETY & INTEGRITY AS PER ISO 9001

6 BENEFITS OF FLANGE MANAGEMENT SYSTEM MANAGEMENT FROM ENGINEERING TO SITE SET-UP MANPOWER AND TOOLS SUPPORT DOCUMENTS MANAGEMENT HISTORICAL DATA TRACKING ISSUANCE OF CERTIFICATES PROPER TAGGING SYSTEM INTEGRITY SAFETY OF PIPELINES FAILURE PREVENTION OF SYSTEMS DUE TO LEAKING JOINTS

7 BENEFIT OF FLANGE MANAGEMENT SYSTEM REDUCE LEAKS DURING START-UP INCREASE PRODUCTIVITY AND PROFITABILITY TO END- USER / CLIENT SAFETY ASSURANCE TO OPERATORS DURING PRODUCTION - LEAKING JOINTS CAUSED GAS EMISSIONS REDUCES IMPROPER ASSEMBLY AND TECHNIQUES USED ELIMINATES INCOMPETENT PERSONNEL OPERATORS QUALIFIED WITH ECITB OR EQUIVALENT STANDARDS MINIMISED RISK OF INJURY WITH CORRECT METHODS AND TOOLS USED

8 SYSTEM OVERVIEW FLANGE MANAGEMENT SYSTEM PRE-ENGINEERING BOLTING ASSEMBLY COMPLETION JOINT REGISTER PREPARATION OF WORK PACKS FLANGE PREPARATION AND INSPECTION MANUAL BOLT TORQUING HYDRAULIC BOLT TORQUING HYDRAULIC BOLT TENSIONING TAGGING OF COMPLETED JOINTS ** REPAIR / FLANGE BREAKOUT Compilation of Joints to be Managed DATA SHEETS JOINTS LOCATION VERIFICATION ISSUANCE OF JCC WITHIN WORK PACKS PERMIT TO WORK (PTW) VERIFICATION OF SYSTEM FOR HANDOVER PRIOR TO JOINT BREAKOUT DATA RECORDS FASTENERS MATERIALS, SPECIFICATIONS AND CONDITION UPDATE JOINT REGISTER JSA CONFIRMATION OF JOINT / VENDOR(S) SPECIFICATIONS PRIOR TO BREAKOUT OF JOINTS ISOMETRICS GASKETS MATERIALS, SPECIFICATIONS AND CONDITION JOINT REGISTER VERIFY FLANGE DETAILS AND SPECIFICATION PROVIDED BY CLIENT P & IDs VERIFICATION OF FLANGES PRIOR TO ASSEMBLY CARRY OUT REPAIR / JOINTS BREAKOUT JOB SAFETY ANALYSIS (JSA) OPEN JOINTS TO BE VERIFIED FOR ITS FLANGE SURFACES & PIPING CLEANLINESS MANUAL BOLT TORQUE / HYDRAULIC BOLT TORQUE / HYDRAULIC BOLT TENSIONING INSPECTION AND APPROVAL FROM CLIENT UPON REPAIR COMPLETION JOINT COMPLETION CERTIFICATE (JCC) INSPECTION CONDUCTED BY CLIENT QA / QC & MCCS RE-CERTIFICATION ISSUANCE OF JCC WITHIN WORK PACKS FINAL INSPECTION AND APPROVAL BY CLIENT UPDATE JOINT REGISTER

9 SYSTEM OVERVIEW FLANGE MANAGEMENT SYSTEM JOINT DATA MANAGEMENT MANUAL BOLT TORQUE HYDRAULIC BOLT TORQUE HYDRAULIC BOLT TENSIONING JOINTS BREAKOUT

10 SYSTEM OVERVIEW FLANGE MANAGEMENT SYSTEM IN SEQUENCES AS FOLLOW; 1 PRE-ENGINEERING JOINT REGISTER PREPARATION OF WORK PACKS FLANGE PREPARATION AND INSPECTION 2 3 BOLTING MANUAL BOLT TORQUE HYDRAULIC BOLT TORQUE HYDRAULIC BOLT TENSIONING ASSEMBLY COMPLETION TAGGING OF COMPLETED JOINTS ISSUANCE OF JCC WITHIN WORK PACKS UPDATE JOINT REGISTER ** REPAIR / FLANGE BREAKOUT

11 SYSTEM OVERVIEW FLANGE MANAGEMENT SYSTEM BRIEF in STAGES AS FOLLOW; PRE-ENGINEERING Pre-Engineering stage is crucial in Flange Management System prior to mobilizing the correct personnel and equipment to site due to: Accurate and precise information to manage service effectiveness To prioritize and ensure the best use of resources This stage comprises of: 1 JOINT REGISTER 2 PREPARATION OF WORK PACKS 3 FLANGE PREPARATION AND INSPECTION JOINT REGISTER A Joint Register will be created to compile all Joints data that are to be managed / tightened / breakout.

12 SYSTEM OVERVIEW PREPARATION OF WORK PACKS The Work Packs will consist of the following documents: DATA SHEETS providing information of Joint specifications, tools required, torque and tension values DATA RECORDS detailing information of materials, specifications and tools used ISOMETRICS given by Client to be extract to Data Sheets and Data Records P & IDs obtained from Client will be organized to Data Sheets and Data Records JOB SAFETY ANALYSIS (JSA) will be designed to suit the project requirements by using Joint Register as a reference JOINT COMPLETION CERTIFICATE (JCC) will be created prior to Bolting and Assembly Completion Stage

13 SYSTEM OVERVIEW FLANGE PREPARATION AND INSPECTION JOINTS LOCATION VERIFICATION will be conducted by MCCS personnel during site inspection FASTENERS MATERIALS, SPECIFICATIONS AND CONDITION will be inspected by MCCS personnel according to Data Records input GASKET MATERIALS, SPECIFICATIONS AND CONDITION will be carefully examined by MCCS personnel based on Data Records obtained VERIFICATION OF FLANGES PRIOR TO ASSEMBLY to ensured specification are inline with the Data Records and Data Sheet OPEN JOINTS TO BE VERIFIED FOR ITS FLANGE SURFACES AND PIPING CLEANLINESS prior to Bolting and Assembly scope INSPECTION CONDUCTED BY CLIENT QA / QC AND MCCS REPRESENTATIVES to ascertained all information obtained are up-todate and witnessed by Client

14 SYSTEM OVERVIEW FLANGE MANAGEMENT SYSTEM BRIEF in STAGES AS FOLLOW; BOLTING After completion of Pre-Engineering Stage, MCCS will mobilize the sufficient number of personnel and correct equipment to site in order to perform the Bolting Stage in which would be WITNESS BY CLIENT. There are three (3) types of bolting methods: MANUAL BOLT TORQUING HYDRAULIC BOLT TORQUING HYDRAULIC BOLT TENSIONING MANUAL BOLT TORQUING A Calibrated Manual Hand Operate Wrench with pre-set / adjustable torque values applying twisting force on fasteners. In accordance to Engineering Construction Industry Training Board (ECITB), manual tightened should not more than 600 lbf.ft (800Nm) HYDRAULIC BOLT TORQUING Twisting force applied on fasteners with Hydraulic Square Drive Power Head / Hydraulic Low Profile Drive Cylinder by setting its torque value on a gauge assembled on a Torque Pump. HYDRAULIC BOLT TENSIONING Tensioning is the direct axial stretching of the bolt to achieve Preload therefore inaccuracy created through frictions are eliminated. Hydraulic tool used to tighten or loosen fasteners by stretching / pulling force instead of applying large torque to the nut

15 SYSTEM OVERVIEW FLANGE MANAGEMENT SYSTEM BRIEF in STAGES AS FOLLOW; ASSEMBLY COMPLETION Upon completion of assembly under the normal circumstances, each Joint would have a tag tied around to confirmed the Joint has been tested and approved by information gathered from Radio-Frequency Identification (RFID) Tagging System. This is referred as TAGGING OF COMPLETED JOINT Upon final inspection and approval obtained from Client, MCCS will conduct ISSUANCE OF JOINT COMPLETION CERTIFICATE (JCC) within the Work Packs and this will be signed-off by both parties i.e. The Client and MCCS The JOINT REGISTER would eventually be updated for safe-keeping and future used should maintenance of piping / shutdown required However, should the joint(s) failed during hydro testing or Nitrogen /Helium Leak Testing, REPAIR / FLANGE BREAKOUT is a MUST to ensure ZERO leaks prior to approving Commissioning Team commencing their start-up / initiate progress.

16 SYSTEM OVERVIEW ** REPAIR / FLANGE BREAKOUT The following documents MUST obtained from Client to ensure relevant data related to the Joint(s) to be repair / breakout prior to work commence : 1 Permit to Work (PTW) 2 Job Safety Analysis (JSA) 3 Joint Register Confirmation of Joint and Vendor(s) specifications verified are inline prior to Repair / Joint Breakout Verifying flange details and specification provided by Client Carried out Repairs / Flange Breakout soon after details confirmed by selecting the correct methods and tools, witness by Client: 1 Manual Bolt Torque 2 Hydraulic Bolt Torque 3 Hydraulic Bolt Tensioning Inspection and Approval from Client upon repair completion Final Inspection and Approval from Client Re-Certification Issuance of Joint Completion Certificate (JCC) within Work Packs Update Joint Register for Safe-Keeping

17 SYSTEM SOFTWARE OVERVIEW INTRODUCTION TO FLANGE MANAGEMENT SOFTWARE Flange Management Software is crucial and plays a key role in modern Oil & Gas Industry to achieve an accurate bolt load calculations To provide timely records to help minimize downtime cost, eliminates issues such as leakage when combining with Nitrogen and Helium Leak Testing Services To increase end-user productivity FMS Software will be used for planning, managing and recording joint details in which MCCS Engineers will recommend the correct tightening methods, tool selection, torque and tension values for each and every Joint. The FMS Software is important especially to calculate the torque / tension value at safety yield percentage for any Special Flanges in which also categorized a Non-Standard Joints

18 SYSTEM SOFTWARE OVERVIEW THE KEY ELEMENT OF FLANGE MANAGEMENT SOFTWARE Database separate into 3 categories: Joint Data Management Equipment Control Personnel Competency Controls all elements associated with bolted joints Seamlessly linked to bolt load calculation engine User friendly interface visual display of project / joint status Single source document management Generate job and joint specific equipment lists Maintain joint historical data Acts as an electronic data bank Enhance reporting skills An additional value added designed features is the ability of its program to transfer database from FMS to the following services: Nitrogen / Helium Leak Testing Services Pipeline Commissioning Services Hook-Up and Pre-Commissioning and Commissioning Services

19 SYSTEM SOFTWARE OVERVIEW FLANGE MANAGEMENT SOFTWARE OVERVIEW

20 SYSTEM SOFTWARE BENEFIT FLANGE MANAGEMENT SOFTWARE BENEFITS Electronically transfers all tensioning pressures, torque values, bolt material, flange class and rating to Database Update Joint Completion Reports and Test Certificates Tracks and Update records as work is completed A summarized progress / report on condition of flanges which are Open- Closed-Tightened-Tested-Leaking OR required on-site machining Import P & IDs and Test Certs Caters for Work Packs & Test Packs in plant sub-systems Records joint tightening, pressure testing and leakage statistic Stores multiple flange records in Banks Identifies equipment specifications and determine Joints requirement Provides a complete traceable recording system for total flange integrity

21 THANKS FOR YOUR ATTENTION